Trane BAYUVCLK001 Installer's Manual

HAZARDOUS VOLTAGE - DISCONNECT POWER BEFORE SERVICING

WARNING:

Installer’s Guide

18-GJ11D1-2

Ultraviolet (UV-C) Lamp Kit for 2-5 Ton Air Handlers

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service

information pack upon completion of work.

Models: BAYUVCLK001 - 40 Watt, 2 Lamp

NOTE: A BAYCC24VK01 can be installed for Series 8 Air Handlers to extend the life of the lamp. This accessory kit will disable the lamp during the heating season (kit is purchased separately).

Cable Tie - Do NOT Cut or Remove

Power Supply Plugs

Used with:

Series 2/4/5/7/8 Air Handlers

Note: 200-230V Units Only

Lamp Bracket Grounds

3.) Ballast and Control Assembly with Door Switch and Wiring Harness

2.) Left Side UV Lamp and Bracket Assembly

Lamp Connector

UV Lamp Control Leads

Kit Contents (Items 4-10 are not pictured)

Item Qty Description

1 1 Right Side UV Lamp and Bracket Assembly 2 1 Left Side UV Lamp and Bracket Assembly 3 1 Ballast and Control Assembly with door switch and wiring harness (rated 200-230 VAC, 50-60 Hz)

4 4 Cable Tie 5 2 Wire Nut 6 2 Screw 7 3 Isopropyl alcohol swab 8 1 Wiring Diagram 9 1 UV Warning Label 10 4 8-32 Hex nut with star washer

Field Supplied

Ammeter with the ability to measure milliamps

1.) Right Side UV Lamp and Bracket Assembly

General

The United States Environmental Protection Agency (EPA) believes that molds and bacteria inside buildings have the potential to cause health problems in sensitive individuals. The manufacturer provides high intensity C-band ultraviolet radiation (UV-C lamp kits) for installation in air handlers for the purpose of reducing microbiological growth (mold and bacteria) within the equipment. Polymer materials that are susceptible to deterioration by the UV-C lamp shall be shielded from direct exposure to the light. This kit was designed with this consideration and the reﬂectors must be in place. In addition, UV-C radiation can damage human tissue, namely eyes and skin. To reduce the potential for inadvertent exposure to the lights by operating and maintenance personnel, an electrical interlock that automatically disconnects power to the lamp is provided integral to the ballast assembly.

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CAUTION

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CAUTION

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Safety Information

SAFETY HAZARD! This information is for use by individu-

als having adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

PERSONAL INJURY HAZARD! Disconnect input

power before beginning installation. Professional installation required per NEC standards. The power supply to this ultraviolet appliance must be disconnected before opening or servicing the unit. Any access panels or doors, within sight of the UV lamps, must be interlocked so as to disconnect power to the UV appliance upon opening or removal.

HAZARDOUS VOLTAGE AND EXPOSURE TO ULTRAVIOLET RADIATION! This product contains

components that emit high-intensity ultraviolet (UV-C) radiation which can be harmful to unprotected eyes and skin. Disconnect all electrical power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

HAZARDOUS VOLTAGE! Multiple power sources may

be present. Disconnect all electrical power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

HAZARDOUS VAPORS! If UV bulbs are broken, an ap-

propriate respirator should be considered to prevent inhalation of mercury vapors. Failure to use a respirator could result in death or serious injury.

LAMPS CONTAIN MERCURY! Follow local and state

guidelines for disposal of mercury bulbs.

BROKEN GLASS! Bulbs are fragile and can be easily

broken. Always use gloves and eye protection when handling these bulbs. Failure to handle bulbs properly may result in minor to moderate injury.

IMPORTANT - Avoid touching the lamp with bare hands as skin oils can accelerate future glass soiling and degrade the lamp performance. Wipe the lamp with a clean cloth and rubbing alcohol or glass cleaner after handling.

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Pre-installation Instructions

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WARNING

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1. Read all instructions before installing UV lamp kit.

2. Avoid touching the lamp with bare hands as skin oils can accelerate future glass soiling and degrade the lamp performance. Wipe the lamp with a clean cloth and rubbing alcohol or glass cleaner after handling.

2. Disconnect all power to the air handler.

HAZARDOUS VOLTAGE! Multiple power sources

may be present. Disconnect all electrical power, including remote disconnects, before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

IMPORTANT: The Right side lamp bracket must be installed before installing the ballast assembly.

IMPORTANT: The lamp brackets and the ballast assembly are provided with aggressive adhesive on back. The adhesive has a peel-off liner. Do not remove the liner until these items have been placed into unit and proper mounting locations within the unit have been confirmed.

IMPORTANT: The two lamp brackets are not symmetrical. One is marked Right and the other is marked Left. These markings apply to an air handler in the vertical upﬂow conﬁguration (with V-shaped coil orientation). It is very important that the right side and left side brackets are placed on the proper side so that UV light is directed toward the center of the coil. Further references to left and right side brackets, top, and bottom in this document assume upﬂow air handler conﬁguration. For other conﬁgurations see the illustration on page 4 for proper bracket location.

NOTE: Use isopropyl alcohol to thoroughly clean and dry the surfaces of the inside coil compartment wall in the areas where the lamp brackets and ballast assembly will be permanently mounted.

NOTE: For new air handler installations, if a UV lamp kit is installed, it is recommended to remove the coil and install the lamp brackets before installing the air handler.

Left

End views

(Front of unit)

Right

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3

Right Bkt

Upflow

Horizontal Right

Downflow

Horizontal Left

Left Bkt

Ballast

Right Bkt

Left Bkt

Ballast

Right Bkt

Left Bkt

Ballast

Right Bkt

Left Bkt

Ballast

UV Lamp Brackets and Ballast locations for Air Handler Orientations

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18-GJ11D1-2

Right Side UV Lamp bracket installation

3. Scribe Horizontal Line

Locating Bottom of Lamp Brac

ket

Lamp Brac

ket - Right Side

the right of the templat

e

.

7.5”

STEP 1. Remove coil panel. See the air handler Installer’s Guide

for additional information if needed.

STEP 2. Cut the cable tie from the right side lamp bracket as-

sembly. Slide the lamp and reﬂector assembly out of the

bracket as shown.

STEP 3. Measure 7.5 inches above the cross bar and make

a mark on the inside of the air handler cabinet (use a

screwdriver or other metal object to scribe line).

STEP 4. Draw a level line to the back of the air handler

cabinet. This line will be used as a guide for the proper

placement of the lamp bracket. The bottom of the lamp

bracket will line up with the scribe line.

End View

18-GJ11D1-2

Cross Bar

5

STEP 5. Once a proper dry ﬁt has been veriﬁed, use the alcohol

7.5”

3

.

Scribe Horizontal Line

Locating Bottom of Lamp Brac

ket

-

swabs to clean the area where the bracket is to be mounted.

STEP 6. Remove liner from adhesive on back of bracket and care-

fully place bracket in coil compartment.

STEP 7. Apply pressure ﬁrmly over all areas of the bracket to

permanently secure the adhesive to the coil compartment

inner wall.

Scribe Line

Left Side UV Lamp bracket installation

STEP 8. Cut the cable tie on the left side lamp bracket assembly.

Slide the lamp and reﬂector assembly out of the lamp bracket

as shown.

STEP 9. Measure 7.5 inches above the cross bar and make a

mark on the inside of the air handler cabinet. Follow the same

process as the right side bracket.

Perform a dry ﬁt test before cleaning the air handler cabinet and

securing the bracket in place.

End View

Cross bar

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Ballast assembly installation

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WARNING

!

HAZARDOUS VOLTAGE! Multiple power sources may

be present. Disconnect all electrical power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Scribe Line

IMPORTANT: For easy of installation, the Power Plugs must be con-

nected before installing the ballast as

IMPORTANT: The ballast assembly is provided with aggressive adhesive on back. The adhesive has a peel-off liner. Do not remove the liner until proper mounting locations within the unit have been confirmed.

NOTE: Use isopropyl alcohol to thoroughly clean and dry the surfaces of the inside coil compartment wall in the areas where the ballast assembly will be permanently mounted.

STEP 10. Disconnect the high voltage wiring harness on the right

side of the indoor coil.

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sembly in the unit.

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Installing power wiring connections

STEP 11. Rest the ballast assembly on top of the cross brace.

IMPORTANT: Do not cut or remove the cable tie that holds the ballast assembly power plugs. The tie prevents strain on the splices.

STEP 12. Connect the ballast assembly in series with the high voltage

leads.

Ballast assembly

Splices

Do not cut or remove

Ballast power plugs

From Coil Compartment

Disconnect air handler power junction plugs

with power plugs

- Unconnected

From Blower Compartment

Ballast assembly with power plugs

- Connected

From Coil Compartment

From Blower Compartment

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18-GJ11D1-2

IMPORTANT: The ballast and bracket assembly is provided with aggressive adhesive on back with peel-off liner. Before removing adhesive liner, temporarily place ballast and bracket assembly into unit to determine proper mounting location.

IMPORTANT: For 17.5” wide cabinets, Do Not remove the adhesive liner. The ballast will be held on by screws only allowing for easy removal to access to the blower plug if needed.

Notch

Air handler

ridge

1

STEP 13. Test ﬁt by carefully placing the ballast and bracket assembly

in the unit.

The ballast should be level and resting on the air handler cross bar.

The notch of the ballast assembly will slide into the ridge of the

air handler. Ensure a solid ﬁt before removing peel-off liner and

exposing the adhesive back.

Note: Be careful not to trap or pinch wires behind or below the ballast assembly.

STEP 14. Once a proper dry ﬁt has been veriﬁed, use the isopropyl alco-

hol swabs to clean the area where the ballast is to be mounted.

1. Remove the adhesive liner and follow the previous steps. Do not

let the adhesive backing touch the cabinet until the ballast is in

place.

2. Once the ballast assembly is in place, apply ﬁrm pressure to secure

to the inner wall of the air handler.

3

2

Ballast assembly front ﬂange

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Ballast assembly bracket that rests upon the cross bar.

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STEP 15. Attach the two supplied screws through the holes in the

bracket. Use a low torque setting when drilling in screws.

IMPORTANT: Use the provided cable ties to secure the wires

behind the cross bar.

Installing UV Lamp wiring connections

NOTE: If the coil was removed before installation, replace the coil

before continuing with the kit installation.

STEP 16. Install the left and right side lamps and reﬂectors into

their brackets.

IMPORTANT: The lamp is held in place by a metal reﬂector that is slightly elliptical. You may need to rotate the lamp when sliding it into the bracket. The lamp will slide in easily once properly aligned.

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Note: There are two connecting harnesses for the lamps. The short

harness is for the right lamp. The longer harness is for the left

lamp.

STEP 17. Route the right hand lamp connector and ground wire har-

ness to the right hand lamp.

STEP 18. Place the ground wire on the stud. Place a factory supplied

nut on the ground stud and tighten it to secure the grounding wire

in place. Then place a second factory supplied nut onto the stud

and tighten in place also.

STEP 19. Support the lamp and place the pin connector on the lamp.

The connector is position sensitive and will slide on easily when

in the proper orientation.

STEP 20. Use one of the provided cable ties to secure the lamp to the

bracket. Loop the cable tie around the lamp bracket and through

the eyelet on the plug.

Ground Nuts

Through eyelet

Cable tie

through

hole in

bracket

STEP 21. Follow the same process for the second lamp.

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Ground Nuts

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STEP 22. There are two yellow control wires in the UV accessory

3

.

Scribe Horizontal Line

Locating Bottom of Lamp Brac

ket

-

Br

-

that are only used with Series 8 air handlers. Connect these two

wires to the two yellow UV Light wires in Series 8 air handlers

as shown using the wire nuts provided. (Refer to air handler

wiring diagram .)

For all other air handlers stow these wires securely and leave them

unconnected.

NOTE: A BAYCC24VK01 can be installed for Series 8 Air Handlers to extend the life of the lamp. This accessory kit will disable the lamp during the heating season (kit is purchased separately).

STEP 23. Use the provided cable ties to secure all wires

STEP 24. Apply wiring diagram label to the inside of the coil com-

partment panel.

IMPORTANT: Make sure all wires are secured completely behind the crossbar and below the coil to prevent wire damage when coil panel is replaced.

STEP 25. Apply UV Hazard warning label to the outside of the coil compartment panel. Place panels back on air handler.

Series 8 Air Handler Only

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Testing for Proper Operation

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WARNING

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WARNING

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WARNING

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WARNING

!

SAFETY HAZARD! This information is for use by individu-

als having adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

PERSONAL INJURY HAZARD! Disconnect input

power before beginning installation. Professional installation required per NEC standards. The power supply to this ultraviolet appliance must be disconnected before opening or servicing the unit. Any access panels or doors, within sight of the UV lamps, must be interlocked so as to disconnect power to the UV appliance upon opening or removal.

PERSONAL INJURY HAZARD! UV-C can be harmful

to unprotected eyes. Do not troubleshoot the lamps by sight.

ELECTRICAL HAZARD! The ballast produces a very

high voltage. Checking for voltage output is likely to cause damage to the meter. Failure to follow this warning could result in property damage, serious personal injury, or death.

STEP 26. Remove the heater panel.

STEP 27. Set the system comfort control to OFF and restore

power.

STEP 28. Use an ammeter to check for current ﬂow on the high volt-

age wires entering the air handler. The lamps should generate

approximately 0.2 amps of current when energized.

The Series 8 air handler with a BAYCC24VK01 kit will energize the

lamps when the system is in the cooling mode. The lamps will

remain energized for 48 hours after then end of cooling mode.

This minimizes the short cycling of the lamps.

Step 29. Replace the heater panel and restore the system comfort

control to its original setting.

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WARNING

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CAUTION

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Maintenance

IMPORTANT: A UV lamp’s characteristic blue glow remains long after its output drops below an effective level and is not a reliable indicator of the need for replacement. Contact your dealer to order and install replacement lamps. To maintain peak efficiency, replace bulb every two years of operation.

IMPORTANT: Use a clean dry cloth (not bare hands) or clean the lamp with alcohol or window cleaner after handling.

IMPORTANT: Contact your Dealer for cleaning and maintenance.

HAZARDOUS VAPORS! If UV bulbs are broken, an

appropriate respirator should be considered to prevent inhalation of mercury vapors. Failure to use a respirator could result in death or serious injury

BROKEN GLASS! Bulbs are fragile and can be easily

broken. Always use gloves and eye protection when handling these bulbs. Failure to handle bulbs properly may result in minor to moderate injury.

IMPORTANT: The lamp must remain clean for optimal performance.

IMPORTANT: UV lamps contain mercury, which is a regulated hazard-

ous waste. Disposal of these lamps is subject to state and federal regulations. Although regulations vary from state to state, disposal requirements for UV lamps typically conform to those for fluorescent bulbs. The Association of Lighting and Mercury Recyclers (ALMR) is a nonprofit, educational, and informative source on mercury recycling and disposal. To learn about individual state recycling programs, visit their web site at http://www.almr.org/index.htm.

UV Lamp Replacement

1. Disconnect all electrical power to the unit.

2. Open the coil panel.

3. Cut the cable tie and remove the plug from the lamp.

4. Wearing soft cloth gloves and safety glasses, use two

hands and ﬁrmly grasp the lamp at nearest end.

5. Slide the lamp and reﬂector shield out of the unit.

6. Remove the reﬂector from lamp.

7. Snap the reﬂector on the new lamp.

8. Install the new lamp.

9. Place the plug on the lamp.

10. Replace the coil panel.

Cleaning the UV Lamps

1. Disconnect all electrical power to the unit.

2. Open the coil panel.

3. Cut the cable tie and remove the plug from the lamp.

4. Wearing soft cloth gloves and safety glasses, use two hands

and ﬁrmly grasp the lamp at nearest end.

5. Remove the lamp and reﬂector from the lamp bracket and

slide the lamp out of the unit.

6. Remove the reﬂector from the lamp.

7. Wipe the lamp with a clean cloth and rubbing alcohol or

glass cleaner. Avoid touching the lamp with bare hands as skin

oils can accelerate future glass soiling and degrade the lamp

performance.

8. Replace the reﬂector on the lamp.

9. Reinstall the lamp.

10. Replace the plug on the lamp.

11. Replace the coil panel.

IMPORTANT: The lamp is held in place by a metal reflector that is slightly elliptical. You may need to rotate the lamp when sliding it into the bracket. The lamp will slide in easily once properly aligned.

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Wiring Diagram

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Trane 6200 Troup Highway Tyler, TX 75707

12/10

Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right to change design and speciﬁcations without notice.